Self-modifying agitation process and apparatus for support removal in additive manufacturing and 3d printed material

ABSTRACT

A process for support material removal for 3D printed parts wherein the part is placed in a media filled tank and support removal is optimized in a multi-parameter system through an artificial intelligence process which may include, but is not limited to, the use of historical data, parametric testing data, normal support removal data, and outputs from other support removal AI models to generate optimally efficient use of each parameter in terms of pulse repetition interval (PRI) and cycle time as defined by pulse width (PW). The input parameters may include heat, circulation, ultrasound and chemical reaction, which are used in sequence and/or in parallel, to optimize efficiency of support removal. Sequentially and/or in parallel, heat, pump circulation and ultrasound may vary in application or intensity. Selection of means of agitation depends on monitored feedback from the support removal tank and application of a statistically dynamic rule based system (SDRBS).

RELATED APPLICATIONS

The present application is a divisional under 37 C.F.R. § 1.53(b) ofU.S. patent application Ser. No. 16/340,647 filed Apr. 9, 2019, now U.S.Pat. No. ______, which is a § 371 nationalization of PCT ApplicationSerial No. PCT/US2017/055957, filed Oct. 10, 2017, designating theUnited States, and this patent document also claims the benefit of U.S.Provisional Patent Application No. 62/406,187, filed Oct. 10, 2016, theentire disclosures of which are incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates generally to a method and apparatus for removingsupport material from unfinished manufactured parts, and, morespecifically, to a method and apparatus for optimizing the supportmaterial removal process for unfinished manufactured parts Which aremade using additive manufacturing techniques such as 3D printing.

BACKGROUND OF THE INVENTION

An unfinished manufactured part may include portions that are necessaryfor manufacture or are a necessary byproduct of the manufacturingprocess, but which are ultimately unwanted in the finished form of thepart. Such portions are referred to herein as “support material” ormerely as “support.” In a conventional support removal machine, anunfinished 3D printed part may be subjected to a process to removeunwanted support material, and thereby provide a finished part. In onesuch process, the part is placed in a liquid filled tank, wheremechanical agitation, abrasion and/or heating of the part occur in orderto remove the support material. Mechanical agitation may occur by movingthe liquid (e.g. via a pump) and/or by using ultrasound. In other suchprocesses, the part is subjected to pressure from a liquid spray and/ortreated with chemical solvents to dissolve support material, and therebyleave the finished form of the part. In some removal processes, the partis placed in a chamber, and a pump is used to circulate fluid throughthe chamber in order to mechanically agitate the part, while heat from aheat source increases the fluid temperature. Under these conditions thesupport material may be removed thermally, chemically, mechanically orvia a combination of two or more of these general methods.

Traditional methods of support removal fail to optimize the supportremoval rates so as to maximize operation relative to a particularmanufactured part. The methods used to control support removal arecomplex and may interrelate, even when applied sequentially. Inaddition, there are often trade-offs between achieving a fast supportremoval and potential damage to the part. Support removal has generallybeen limited to the use of one or two removal methods at a time, or usedin systems where each removal method may have separate control systemsthat may be independently evaluated and adjusted on a periodic basisunder controlled settings. The interrelationship between removalmethods, such as agitation, temperature, chemical and fluid flow, arelargely ignored despite the fact that one type of removal method mayfacilitate or hinder another removal method.

Furthermore, unfinished manufactured parts come in many sizes, shapes,and materials. Some removal methods are better suited than others,depending on the particular size, shape, and material.

Existing machines and processes for support removal are prone to causingdamage to the part due to over-use of a particular removal method suchas heat, chemical treatment, or abrasion. For example, excessive heatcan cause weakening of delicate portions of a part, which may ultimatelyresult in damage to the put. And, the use of ultrasonic agitation mayresult in heating of the part without a corresponding temperatureincrease of the media in which the part resides. The result may be anunexpected and unwanted increase in the part temperature, which resultsin damage to delicate portions of the part. In short, adverse impactsmay arise from numerous methods interacting with one another, therebyresulting in suboptimal application of such methods for a particularpart.

Suboptimal application of any one method may lead to inefficient use ofenergy and/or time. For example, excessive use of ultrasonic agitationmay result in excessive heat generation and may require downtime whilethe system is cooled to a more optimal temperature, which takes time,and thus causes a less efficient process. Inefficiencies can manifestthemselves in the form of taking too long to fully remove supportmaterial from the part, and/or removing too much material from the part,and/or ruining the surface finish of the part. Such losses in efficiencyincrease costs of operation.

Another example of an inefficiency is the suboptimal application ofagitation, which can damage the part or lead to a ruined surface finishof the part. If the intensity of the agitation is too high, or ifagitation is carried out too long, the support material may be fullyremoved, but the surface of the part may be eroded to an undesirableextent. The resulting parts may be unacceptable, resulting in a need todiscard the part and to try again.

Compounding the problems arising from the use of conventional machinesfor support removal is an inability to precisely control removalmethods. Often, conventional machines provide the user with an abilityto merely engage or not engage a particular method, such as temperature,chemical pH, or agitation, which effectively amounts to providing an“on/off switch.” For example, when removing support material usingagitation, a circulating pump may be typically set at 100% power or 0%power. By limiting a user's choice to only 100% or 0%, the result may bein an inability to optimize the process, and an increase in thepotential for damage to the part.

Multiple support removal methods operating simultaneously in a givenmachine could result in greater efficiency. However, traditional methodsfor managing multiple types of support removal methods are currentlylimited to (a) random application of methods, (b) manual application ofmethods, and (c) time-based sequencing of varying methods. In mostcases, the methods are activated based on predetermined criteria,established protocols, sequential methods, time-based approaches,operator judgment, or combinations thereof, and result in indiscriminateremoval of support material, and fail to properly take into account thedegree to which support material should be removed from an unfinishedpart. For example, a finishing shop that uses only time-based methodswill find that such methods are highly inefficient due to the widevariety of parts and materials that may be used in a particular machine.For example, a time-based method could easily dissolve a whole part ifthe run time was not set properly, or some other fixed parameter was tooaggressive for the particular part.

Operators of support removal machines face the difficult task ofcontrolling process parameters that have nonlinear relationships, someof which are discussed above, while maintaining capabilities to removesupport material in a timely manner. On top of those challenges is thefact that different parts may react differently to the same processconditions. Simultaneously optimizing heat rate, ultrasonic agitation,pH, part rotation rate, or other aspects is at best challenging, and maybe unrealistic for an operator to do manually. In addition, industrydemands may impose further restrictions that impose significantrestrictions on operating conditions for support removal machines andtheir operators.

To increase efficiency, support removal machines can be subject to rulesformulated from operator experiences, design data, general scientificprinciples, and periodic testing. However, such rules alone likelycannot accommodate the diverse set of operating conditions that may beencountered by operators on a daily basis. Furthermore, time-based orrandom varying parameter-based systems alone may not be the best optionsdue to the complexity of the individual parts and methods of agitation.

Thus, there has been a long-felt need for a method and apparatus forautomatically removing support material from parts, either made fromtraditional or additive manufacturing techniques, and optimizing thesupport material removal process as the process progresses over definedtime intervals by varying certain parameters of the process.

BRIEF SUMMARY OF THE INVENTION

The present invention may be embodied as a method for removing unwantedmaterial from an unfinished manufactured part. Such a method may includefeatures for optimizing the operation of a support removal machine thathas a plurality of removal methods. In one such method an operationmodel may be generated and used to control operation of the supportremoval machine. The model may be provided with a plurality of inputparameters associated with operation of the support removal machine, andusing those input parameters, the model may generate one or more outputparameters. Each output parameter may be associated with a goal for thesupport removal machine. The method may be carried out so as to identifyone or more consecutive time increments, and during each time incrementmake one or more decisions that seek to achieve one or more of thedesired goals. At least one of the decisions is associated with at leastone discrete variable of operation corresponding to the support removalmachine and based on the model. The support removal machine may beoperated according to the decisions.

For example, in one such method that is in keeping with the invention, a3D printed part having support material may be placed in a tank with aliquid detergent. Initial parameters within the tank, including, but notlimited to temperature and pH, may be characterized and used todetermine the amount and type of energy that should be applied to thepart in order to remove the support material, initial parameters for thesupport removal machine may be based on operator experiences, staticdesign data, general thermal principles and/or periodic testing. Forexample, a solid or dense object may require a greater initial heatingtime than a hollow object. Initial settings may be predicted based onprevious experience with similar objects and thermal principles known tothe operator, where the operator may be a person or a computer program.

In some embodiments of the invention, initial process parameters, suchas a temperature around an initial predicted temperature setting, may beselected by a user and the effects within the tank may be measured overa time interval to determine an optimal value for a complete process.

Once a part having a support removal structure is placed in the tank, apump may be used to causes media (such as a liquid) to flow through thetank. The media flow may cause one or more parts in the media to rotateand/or maintain a general position within the tank, and after a periodof time, measurements of the part may be taken. Such measurements mayinclude the amount of support material removed, or the amount of supportmaterial remaining to be removed. Sensors mounted in or near the tankmay be used to obtain such measurements. In response to thosemeasurements, the removal process parameters may be altered and/oradjusted to achieve a desired outcome. After making a plurality of suchmeasurements, the particular series of operating parameters carried outby the support removal machine may become optimized for a particularpart, and such a system may enable better predictions achieving moreefficient removal of support removal in the future, not only for thatparticular part, but also for other parts like it. In doing so, initialpredictions of operating parameters may be made more accurately, andsubsequent alterations to the method and/or adjustments to theparameters may be smaller.

Depending on the characteristics of a particular part, a preferredmethod of agitation, such as chemical or thermal degradation of supportmaterial, may be used. However, when application of a preferred methodbecomes suboptimal, an alternative method of agitation may be activatedduring a down period for a preferred method. The alternative method ofagitation is determined after a defined time interval if suchalternative method would increase the efficiency of the process.Following the down period for a preferred method, the support removalsystem of the present invention may return to the preferred method untilan upper limit of a design parameter, such as temperature, is reachedagain, whereupon the preferred method is de-activated again for a downperiod. If a design parameter exceeds an upper limit, then the processwill become suboptimal. The support removal machine has sensors that mayinclude temperature and/or pH sensors to receive feedback andalternatively deactivate different methods of agitation.

To limit damage to the part, each method of agitation is monitored tomaximize support removal while leaving the part without support materialintact. With particular regard to plastic 3D printed parts, it iscritical to monitor each means of agitation to limit temperatureincrease of the part because plastic materials may be deformed whentemperature becomes too high. Unlike with existing support removalsystems, in the present invention a variety of agitation means areemployed in sequence or in parallel depending on the feedback to anagitation algorithm (AGA). The process of the present invention utilizesheat, pumping, ultrasound and chemical means to enhance support removal.Agitation with ultrasound results in cavitation of detergents in theimmediate vicinity of the support material while chemical reactions andpumping may work synergistically to promote support material removal.

Additionally, the present invention broadly includes a method ofremoving support material from a part, including placing a part withsupport material within a chamber, the chamber having a media arrangedwithin, setting a set of first parameters of the media for a first timeinterval, measuring a first effect the media having the first parametersimparted on the support material over the first time interval prior tothe end of the first time interval via a first sensor operativelyarranged to view the part within the chamber, analyzing the measurementsfrom the first sensor, determining a set of second parameters of themedia for a second time interval, adjusting the media to the secondparameters for the second time interval, repeating the method over aplurality of consecutive time intervals until a run time for the methodhas been reached, and removing the part from said chamber after the runtime for the method has been reached.

Moreover, the present disclosure broadly describes an apparatus forsupport material removal, including a chamber operatively arranged toreceive a part having support material, a media placed within thechamber, the media encompassing the part, a temperature control unitarranged to vary a temperature of the media within the chamber, anagitator arranged to agitate the media within the chamber, a pumpoperatively arranged to circulate the media within the chamber, a firstsensor operatively arranged to detect a first set of parameters of themedia, and a control unit communicatively connected to the first sensor,wherein during operation of the apparatus, the first sensor transmitsthe first set of parameters to the control unit, the control unitanalyzes the first set of parameters to determine a second set ofparameters of the media, the control unit outputting the second set ofparameters to the temperature control unit, the pump, and the agitator.

Even further, the present disclosure broadly describes a method ofremoving support material from a part, including determining a first setof parameters of a media arranged within a chamber, subjecting a partwith support material to the media having the first set of parametersover a first time interval, determining a second set of parameters ofthe media prior to the end of the first time interval, subjecting thepart with support material to the media having the second set ofparameters over a second time interval, the second time interval beingshorter than the first time interval, repeating the method over aplurality of consecutive time intervals until a run time for the methodhas been reached, and removing the part from the media after the runtime for the method has been reached.

A primary object of the present invention is to provide a supportremoval optimization system, method, and apparatus that utilizescalculations based on historical and real-time operating data acquiredfrom support removal control systems.

Additionally, another object of the present invention is to provide asupport removal optimization system and method that optimally determineswhen and which support removal agitation component to select and signalfor activation.

Moreover, another object of the present invention is to provide a methodfor optimizing the operation of a support removal machine wherein one ormore decisions are determined for at least one consecutive timeincrement, where at least one of the decisions is associated with adiscrete variable for operation of a support removal agitationcomponent.

These and other objects, features and advantages of the presentinvention will become readily apparent upon a review of the followingdetailed description, in view of the drawings and appended claims. aims.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature and mode of operation of the present invention will now bemore fully described in the following detailed description of theinvention taken with the accompanying figures, in which:

FIG. 1 is a perspective view of a support material removal apparatus;

FIG. 2 is a side view of the support material removal apparatus depictedin FIG. 1 ;

FIG. 3A is a cross-sectional view of the support material removalapparatus taken generally along line 3A-3A in FIG. 2 ;

FIG. 3B is a cross-sectional view of the support material removalapparatus taken generally along line 3B-3B in FIG. 2 ;

FIG. 4 is a perspective view of an internal chamber arranged within thesupport material removal apparatus depicted in FIG. 3A;

FIG. 5 is a flowchart illustrating an overview of the general operationof a support material removal method according to the present invention;

FIG. 6 is a flowchart describing optimization of the support materialremoval method according to a first embodiment of the present invention;and,

FIG. 7 is a flowchart describing optimization of the support materialremoval method according to a second embodiment of the presentinvention.

DETAILED DESCRIPTION

At the outset, it should be appreciated that like drawing numbers ondifferent drawing views identify identical, or functionally similar,structural elements of the invention. It is to be understood that thisinvention is not limited to the disclosed aspects.

Furthermore, it is understood that this invention is not limited to theparticular methodology, materials, or modifications described and, assuch, the invention may vary from that which is disclosed herein. It isalso understood that the terminology used herein is for the purpose ofdescribing particular aspects.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood to one of ordinary skill inthe art to which this invention pertains. It should be understood thatany methods, devices or materials similar or equivalent to thosedescribed herein can be used in the practice or testing of the methodand apparatus.

Furthermore, as used herein, “and/or” is intended to mean a grammaticalconjunction used to indicate that one or more of the elements orconditions recited may be included or occur. For example, a devicecomprising a first element, a second element and/or a third element, isintended to be construed as any one of the following structuralarrangements: a device comprising a first element; a device comprising asecond element; a device comprising a third element; a device comprisinga first element and a second element; a device comprising a firstelement and a third element; a device comprising a first element, asecond element and a third element; or, a device comprising a secondelement and a third element.

Furthermore, as used herein, “optimization” is intended to mean an act,process, or methodology of making something (such as a design, system,or decision) as fully perfect, functional, or effective as possible. Forexample, an optimal process will achieve the best results possible fromthe process under the parameter ranges the process is allowed to operatein Additionally, as used herein, “determining” is intended to mean theact of receiving information from a sensor and executing an algorithmusing that information to produce an output, for example via a computerthat is programmed according to that algorithm.

Adverting now to the figures, FIG. 1 is a perspective view of supportmaterial removal apparatus 100. Support material removal apparatus 100broadly includes chamber section 102, control unit section 104, controlinput screen 106, access doors 108A, 108B, and 108C, and lid 110. Withinchamber section 102 is chamber 120 (shown in FIG. 3A). Within controlunit section 104 is control unit 140. Control input screen 106 may bepositioned so that a user can input certain operation parameters to becarried out by apparatus 100.

FIGS. 3A and 3B show that chamber 120 may be arranged within chambersection 102, and that within chamber section 102 may be a filter 122, apump 124, pressure sensors 130, part sensor 136, cooling unit 138,ultrasonic transducer 142 (shown in FIG. 3B), heating unit 150 (shown inFIG. 4 ), and temperature sensor 152. Media 154 may be operativelyarranged within chamber 120. Media 154 can be a fluid or a plurality ofabrasive bodies, or a combination thereof. Pump 124 may be connected tochamber 120 via pipes 126, which secure to chamber 120 at positionsaround the perimeter of chamber 120. Such an arrangement and with properorientation of the pipes 126 relative to chamber 120 the media 154 maybe caused to move to form a vortex within chamber 120. This vortexallows for an even and complete mixing of parts 160 which have supportmaterial 162 that must be removed. It is desirable to have parts 160evenly and completely mixed with the media to ensure uniform removal ofsupport material and/or surface finish. Part sensor 136 may beoperatively arranged within chamber section 102 and may be capable ofmonitoring the effect media 154 has on put 160 including monitoring ofsupport material 162. For example, part sensor 136 may be used tomonitor the amount of support material 162 which has been removed over aspecific time interval. Part sensor 136 may be an optical, infrared,thermal, or acoustic sensor, which can detect the rate of deteriorationof part 160 and support material 162. Cooling unit 120 can be anysuitable cooling device, and may include a fan. The cooling unit 120 andheating unit 150, can be used to cool or heat media 154 within chamber120 during operation of apparatus 100. Pressure sensors 130 may bearranged within chamber 136 to detect the pressure of media 154 at thedischarge of pump 124.

Arranged within control unit section 104 of apparatus 100 may be controlinput screen 106, control unit 140, and ultrasonic wave generators 132.Control input screen 106 may be communicatively connected to controlunit 1.40 via wire 141. Control unit 140 may be communicativelyconnected to pump 124, pressure sensors 130, part sensor 136, coolingunit 138, heating unit 150, ultrasonic wave generators 132, andtemperature sensor 152.

FIG. 3B is a cross-sectional view of the support material removalapparatus 100 taken generally along line 3B-3B in FIG. 2 . As shown inFIG. 3B, ultrasonic transducer 142 may be mounted and oriented relativeto chamber 120 in order to agitate media 154. It should be appreciatedthat other types of agitators may be used in order to properly agitatemedia 154. Next to chamber 120 is overflow chamber 148 (shown in FIG.3B). Overflow chamber 148 is arranged to allow media 154 to flow fromchamber 120, but prevent part 160 from leaving chamber 120. Fromoverflow chamber 148, the media flows to the suction side of pump 124without. Media 154 flows over weir 146 into overflow chamber 148. Asmedia 154 flows over weir 146, media passes through filtering screen144, which filters out larger pieces of part 160 or support material 162which may have broken off during the support removal process.

FIG. 4 is a perspective view of chamber 120. Heating unit 150 may besecured to chamber 120. Temperature sensor 152 may be arranged behindheating unit 150 and may be also secured to chamber 120. Chamber 120includes opening 121 which allows an operator to place parts in chamber120. Opening 121 can be accessed by lifting lid 110 (shown in FIG. 1 )of chamber section 102.

FIG. 5 is a flowchart that generally describes operation of a supportmaterial removal method. In such a method, a part 160 is placed 200within chamber 120. Part 160 can be made using traditional manufacturingtechniques, such as casting, forging, or injection molding, or can bemade using additive manufacturing techniques such as 3D printing. Part160 generally comprises unwanted material, which is referred to hereinas support material 162, that is often a manufacturing by-product, suchas flash from forging or buns from machining of part 160. After part 160is placed within chamber 120, the pump 124 may be activated 202 to beginthe flow of media 154 around part 160. Due to the activation 202 of pump124, part 160 rotates 204 in chamber 120. The vortex which may be formedin media 154 as a result of activating 202) the pump 124 rotates part160 within the media 154 to achieve surface coverage of part 160. Aspart 160 rotates in chamber 124, ultrasonic transducer 142 may beactivated 266. Activation 206 of ultrasonic transducer 142 agitates themedia 154 that surrounds part 160 in order to increase the removal rateof support material 162 from part 160. While agitation of media 154occurs, part 160 continues to rotate within chamber 120 to ensurecomplete part coverage of the part 160 by the media 154. After theprocess removes unwanted support material 162, the finished part 160 isremoved 210 from chamber 120.

FIG. 6 is a flowchart showing an embodiment of a method of renewingsupport material from an unfinished manufactured part. A user places apart in the chamber 120 filled with media 154. At step 300, a userchoosing certain parameters of the whole process, such as the run time,temperature, and intensity level. Intensity level is a factor whichcorrelates to how aggressively support material 162 is removed from part160. By selecting the intensity level, corresponding preselectedsettings are automatically selected for removal methods such asultrasonic agitation level and/or pump pressure, and/or temperature ofmedia 154. Using the inputted parameters from step 300, control unit 140will then provide these parameters to algorithm step 301. At step 301,an algorithm determines how fast the removal methods will increase toreach the selected parameters. Since ultrasonic agitation, pumppressure, media and temperature all have an effect on the part 160, theinteraction of each parameter with one another may be balanced in orderto make the most predictable process by knowing the extent at which eachparameter can influence the others when varying that parameter. Usingthe settings of step 300, the algorithm step 301 determines the startingpoints for each removal method, such as for agitation level, pumppressure, temperature, and the time that each removal method will becarried out at a particular setting. Each parameter will be monitoredindividually and in parallel with one another over defined timeintervals. For example, step 302 includes setting the temperature to theintensity level determined by algorithm step 301. Step 304 includesrunning the process at the set temperature from step 302 over a definedfirst time interval. And, at step 306 the temperature is checked.

Similarly, step 312 includes setting ultrasonic agitation to the levelfrom algorithm step 301. Step 314 includes running the process at theset agitation level from step 312 over the defined first time interval.And, at step 316 the agitation level is checked.

Step 322 includes setting the pump pressure to the level from algorithmstep 301. Step 324 includes running the process at the set pump pressurefrom step 312 over the defined first time interval. And, at step 326 thepump discharge pressure is checked.

Additionally, step 332 includes setting the media pH to the level fromalgorithm step 301. Step 334 includes running the process at the setmedia pH level from step 332 over a defined first time interval. And, atstep 336 the pH of the media is checked.

Once checked 306, 316, 326, 336, the values of temperature, agitationlevel, pump discharge pressure, and pH of the media can be fed back toalgorithm step 301, where a second set of parameters for temperature,agitation level, pump pressure, and oil may be determined. Using thesecond set of parameters, the process is then run again over a definedsecond time interval. It should be appreciated that the second timeinterval may be shorter than the first time interval. The process canrun through a plurality of time intervals prior to finishing theprocess. As such, the process is iterative, which works to optimize thesupport removal process within a specified time duration. This processoverall keeps the parameters close to a desired level at each iterationof the process. In a preferred embodiment, algorithm step 301 utilizes aparameter database which has been formulated from a plurality of processruns on other parts using the same apparatus and method. Analysis ofthese parameters may allow for optimization of the process with respectto a particular part process.

FIG. 7 is a flowchart showing another embodiment of a support materialremoval method. This second embodiment of the support material removalprocess is similar to the first embodiment of the process shown in FIG.6 , except that additional step 350 is included. Step 350 is thescanning of the part within the machine while the support material isbeing removed. Such scanning may be used to determine (a) the amount ofsupport material removed from the part, (b) the amount of supportmaterial remaining on the part, or (c) both (a) and (b). Thisinformation, or measurement, may be sent to algorithm step 301 as datawhich is used to determine parameter levels for the process. Byevaluating the measurement from step 350, the process will be able toadapt depending on how effective the process has been during one or moreprior time intervals. Additionally, it should also be appreciated thatstep 350 can be a real-time measurement of the support material on thepart, or an evaluation of a computer aided design (CAD) model of thepart. The information obtained by scanning 350 the part may be used bythe algorithm at step 301 to more efficiently make a determination ofthe parameters selected for the process.

In the foregoing description, example embodiments are described. Thespecification and drawings are accordingly to be regarded in anillustrative rather than a restrictive sense.

It will be appreciated that various aspects of the above-disclosedinvention and other features and functions, or alternatives thereof, maybe desirably combined into many other different systems or applications.Various presently unforeseen or unanticipated alternatives,modifications, variations, or improvements therein may be subsequentlymade by those skilled in the art which are also intended to beencompassed by the following claims.

LIST OF REFERENCE NUMERALS

-   -   100 support material removal apparatus    -   102 chamber section    -   104 control unit section    -   106 control input screen    -   108A access door    -   108B access door    -   108C access door    -   110 lid    -   120 chamber    -   121 opening    -   122 filter    -   124 pump    -   126 pipes    -   130 pressure sensor    -   136 sensor    -   138 cooling unit    -   142 ultrasonic transducer    -   144 filtering screen    -   146 weir    -   148 overflow chamber    -   150 heating unit    -   152 temperature sensor    -   154 media    -   160 part    -   162 support material    -   200 placement step    -   202 activation step    -   204 rotation step    -   206 agitation step    -   210 removal step    -   300 initial parameter entry step    -   301 algorithm step    -   302 setting temperature step    -   304 running process step    -   306 temperature check step    -   312 setting agitation level step    -   314 running process step    -   316 agitation level check step    -   322 setting pump pressure step    -   324 running process step    -   326 pump pressure check step    -   332 setting pH/liquid level step    -   334 running process step    -   336 pH liquid level check step    -   350 scanning step

What is claimed is:
 1. An apparatus for support material removal,comprising: a chamber operatively arranged to receive a part havingsupport material; a media placed within said chamber, said mediaencompassing said part; a temperature control unit arranged to vary atemperature of said media within said chamber; an agitator arranged toagitate said media within said chamber; a pump operatively arranged tocirculate said media within said chamber; a first sensor operativelyarranged to detect a first set of parameters of said media; and, acontrol unit communicatively connected to said first sensor, whereinduring operation of the apparatus, said first sensor transmits saidfirst set of parameters to said control unit, said control unit analyzessaid first set of parameters to determine a second set of parameters ofsaid media, said control unit outputting said second set of parametersto said temperature control unit, said pump, and said agitator.
 2. Theapparatus for support removal recited in claim 1, wherein said part ismade from additive manufacturing and said support material is createddue to the additive manufacturing process.
 3. The apparatus for supportremoval recited in claim 1, further comprising a second sensoroperatively arranged to view said part within said chamber to take ameasurement of an amount of said support material removed from saidpart, said second sensor transmits said measurement to said controlunit, said measurement analyzed by said control unit in combination withsaid first set of parameters to determine said second set of parametersof said media.
 4. The apparatus for support removal recited in claim 3,wherein said second sensor is an optical, infrared, thermal, or acousticsensor.
 5. The apparatus for support removal recited in claim 1, whereinsaid media is a fluid, a plurality of abrasive bodies, or a combinationof both.
 6. The apparatus for support removal recited in claim 1,wherein said parameters comprise media pressure, agitation intensity, ortemperature.
 7. A method of removing support material from a part,comprising: determining a first set of parameters of a media arrangedwithin a chamber; subjecting a part with support material to said mediahaving said first set of parameters over a first time interval;determining a second set of parameters of said media prior to the end ofsaid first time interval; subjecting said part with support material tosaid media having said second set of parameters over a second timeinterval, said second time interval being shorter than said first timeinterval; repeating said method over a plurality of consecutive timeintervals until a run time for said method has been reached; and,removing said part from said media after said run time for said methodhas been reached.
 8. The method of support material removal as recitedin claim 7, further comprising: measuring an effect said media has onsaid support material over said first time interval via a sensoroperatively arranged to view said part during said process; comparingsaid effect said media has on said part over said first time interval toa computer-generated model of said part; and, determining an amount ofsaid support material which remains attached to said part.
 9. The methodof support material removal as recited in claim 7, further comprising:receiving a data set from said user in order to set said set of firstparameters of said media; measuring the temperature, agitation level, orpump pressure of said media via a sensor operatively arranged to read indata from said media; and, determining the second set of parameters ofsaid media by using said measurements of said media.
 10. The method ofsupport material removal as recited in claim 7, wherein said media is afluid, a plurality of abrasive bodies, or a combination of both.
 11. Themethod of support material removal as recited in claim 7, wherein saidset of first parameters is determined from a parameter history database.12. The method of support material removal as recited in claim 7,wherein an effect said media has on said part over said first timeinterval is compared to a computer-generated model of said part todetermine an amount of support material which remains attached to saidpart.
 13. The method of support material removal as recited in claim 7,further comprising measuring an effect said media having said secondparameters imparts on said support material over said second timeinterval via a first sensor, said first time interval being longer inlength than said second time interval.
 14. An apparatus for removal ofsupport material from a 3D printed part, comprising: a chamber forcontaining a fluid media; an agitator operative to agitate the fluidmedia; a sensor operative to detect at least one of the 3D printed part,the support material, or the fluid media during agitation of the fluidmedia; and a control unit configured to be responsive to an output ofthe sensor and based on said output operative to determine a change inan operating parameter, and further said control unit configured toapply said change in the operating parameter to operation of theapparatus.
 15. The apparatus of claim 14 further comprising: a heatingunit operative to heat the fluid media.
 16. The apparatus of claim 14further comprising: a. a transducer operative to apply ultrasonic wavesto the fluid media.
 17. The apparatus of claim 14 further comprising: a.a pump operative to circulate the fluid media in the chamber.
 18. Theapparatus of claim 14 wherein said change in the operating parameterincludes at least one of temperature or agitation.
 19. The apparatus ofclaim 14 wherein said sensor detects at least one of: temperature, pH,agitation of said fluid media, pressure, an amount of support materialremaining on the 3D printed part, or an amount of support materialremoved from the 3D printed part.
 20. The apparatus of claim 14 whereinsaid sensor is an optical, infrared, thermal, or acoustic sensor.